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Heat Exchanger
Heat Exchanger
A heat exchanger is a device used to transfer heat between a solid object and
a fluid, or between two or more fluids. The fluids may be separated by a solid
wall to prevent mixing or they may be in direct contact. They are widely used
in space heating, refrigeration, air conditioning, power stations, chemical
plants, petrochemical plants, petroleum refineries, natural-gas processing,
and sewage treatment. The classic example of a heat exchanger is found in
an internal combustion engine in which a circulating fluid known as engine
coolant flows through radiator coils and air flows past the coils, which cools
the coolant and heats the incoming air. Another example is the heat sink,
which is a passive heat exchanger that transfers the heat generated by an
electronic or a mechanical device to a fluid medium, often air or a liquid
coolant.
Keywords:
transfer heat between a solid object and a fluid (fluids).
In parallel-flow heat exchangers, the two fluids enter the exchanger at the
same end, and travel in parallel to one another to the other side.
Others
Parallel
flow
Counter
flow
The driving temperature across the heat transfer surface varies with position,
but an appropriate mean temperature can be defined. In most simple systems
this is the "log mean temperature difference" (LMTD). Sometimes direct
knowledge of the LMTD is not available and the NTU method is used.
NTU:
The Number of Transfer Units (NTU) Method is used to calculate the rate of
heat transfer in heat exchangers when there is insufficient information to
calculate the Log-Mean Temperature Difference (LMTD). In heat exchanger
analysis, if the fluid inlet and outlet temperatures are specified or can be
determined by simple energy balance, the LMTD method can be used; but
when these temperatures are not available The NTU or The
effectiveness method is used.
Counter
flow
Severall th
S thermall d
design
i features
f t mustt be
b considered
id d whenh d designing
i i ththe
tubes in the shell and tube heat exchangers: There can be many variations on
g Typically,
the shell and tube design. yp y, the ends of each tube are connected to
plenums (sometimes called water boxes) through holes in tubesheets. The
tubes may be straight or bent in the shape of a U, called U-tubes.
Shell side
nozzle
Channels
Channel
Channels
Nozzles
Pass
divider
Plenum / Water
Box
This is straight tube, two pass
tube side. Other configuration
Channel include U-tube two pass tube side
Cover
Plenum (water-box)
or Channel?
Tube length: heat exchangers are usually cheaper when they have a
smaller shell diameter and a long tube length. Thus, typically there is an
aim to make the heat exchanger as long as physically possible whilst not
exceeding production capabilities. However, there are many limitations for
this, including space available at the installation site and the need to
ensure tubes are available in lengths that are twice the required length
(so they can be withdrawn and replaced). Also, long, thin tubes are
difficult to take out and replace.
Tube length: heat exchangers are usually cheaper when they have a
smaller shell diameter and a long tube length. Thus, typically there is an
aim to make the heat exchanger as long as physically possible whilst not
exceeding production capabilities. However, there are many limitations for
this, including space available at the installation site and the need to
ensure tubes are available in lengths that are twice the required length
(so they can be withdrawn and replaced). Also, long, thin tubes are
difficult to take out and replace.
Tube corrugation: this type of tubes, mainly used for the inner tubes (?) ,
increases the turbulence of the fluids and the effect is very important in
the heat transfer giving a better performance.
1.25 x d min
Charlie Chong/ Fion Zhang
Tube Corrugation - Increases the turbulence of the fluids and the effect is
very important in the heat transfer giving a better performance.
The triangular patterns are employed to give greater heat transfer as they
force the fluid to flow in a more turbulent fashion around the piping.
Square patterns are employed where high fouling is experienced and
cleaning is more regular.
The most common type of baffle is the segmental baffle. The semicircular
segmental baffles are oriented at 180 degrees to the adjacent baffles
forcing the fluid to flow upward and downwards between the tube bundle.
Baffle spacing is of large thermodynamic concern when designing shell
and tube heat exchangers. Baffles must be spaced with consideration for
the conversion of pressure drop and heat transfer. For thermo economic
optimization it is suggested that the baffles be spaced no closer than 20%
of the shell’s inner diameter. Having baffles spaced too closely causes a
greater pressure drop because of flow redirection.
The other main type of baffle is the disc and doughnut baffle, which consists
of two concentric baffles. An outer, wider baffle looks like a doughnut, whilst
the inner baffle is shaped like a disk. This type of baffle forces the fluid to
pass around each side of the disk then through the doughnut baffle
generating a different type of fluid flow.
Fixed tube liquid-cooled heat exchangers especially suitable for marine and
harsh applications can be assembled with brass shells, copper tubes, brass
baffles, and forged brass integral end hubs.
0.20 x D min
A shell and tube heat exchanger is a class of heat exchanger designs. It is the
most common type of heat exchanger in oil refineries and other large
chemical processes, and is suited for higher-pressure applications. As its
name implies, this type of heat exchanger consists of a shell (a large pressure
vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and
another fluid flows over the tubes (through the shell) to transfer heat between
the two fluids. The set of tubes is called a tube bundle, and may be composed
of several types of tubes: plain, longitudinally finned, etc.
Heat exchangers with only one phase (liquid or gas) on each side can be
called one-phase or single-phase heat exchangers. Two-phase heat
exchangers can be used to heat a liquid to boil it into a gas (vapor),
sometimes called boilers, or cool a vapor to condense it into a liquid (called
condensers), with the phase change usually occurring on the shell side.
Boilers in steam engine locomotives are typically large, usually cylindrically-
shaped shell-and-tube heat exchangers. In large power plants with steam-
driven turbines, shell-and-tube surface condensers are used to condense the
exhaust steam exiting the turbine into condensate water which is recycled
back to be turned into steam in the steam generator.
Charlie Chong/ Fion Zhang
Heat Exchanger Phases
Single
Phase
Heat Heat
Exchanger
Exchanger Boiler
Phases
Duo
Phases
Condenser
Pas Divider
Counter current heat exchangers are most efficient because they allow the
highest log mean temperature difference between the hot and cold streams.
Many companies however do not use two pass heat exchangers with a u-
tube because they can break easily in addition to being more expensive to
build. Often multiple heat exchangers can be used to simulate the counter
current flow of a single large exchanger.
B: F: M:
D: H: P:
K: T:
U-TUBE BUNDLE
W:
BEM
Bonnet (Intergral Cover), One Pass Shell, Fixed Tubesheet BonnetFixed
tubesheet heat exchanger. This is a very popular version as the heads can be
removed to clean the inside of the tubes. The front head piping must be
unbolted to allow the removal of the front head, if this is undesired this can be
avoided by applying a type A front head. In that case only the cover needs to
be removed. It is not possible to clean the outside surface of the tubes as
these are inside the fixed part. Chemical cleaning can be used. Shown is a
version with one shell pass and two tube passes.
AEM
Channel with Removable Cover, One Pass Shell, Fixed Tubesheet Bonnet.
This is almost the same type of heat exchanger as the first BEM, the
removable cover allows the inside of the tubes to be inspected and cleaned
without unbolting the piping.
Note that the bundle can not be pulled from the front end. For maintenance
both the front and rear end head, including the backing device, must be
disassembled. If pulling from the front head is required a type AET should be
selected.